Chapter 5 Protective Packaging and Materials Handling

Learning Objectives To know how product features affect packaging and materials handling To identify the functions performed by protective packaging To analyze the utilization of unit loads in materials handling To appreciate how the environmental protection movement has affected packaging and package choice To learn materials handling principles © 2008 Prentice Hall

Protective Packaging and Materials Handling Key Terms Building-blocks concept Closed-loop systems Container Cube out Ergonomics Materials handling Package testing Packaging Pallet (skid) Key Terms Part-to-picker system Picker-to-part system Shrink-wrap Slip sheet Unitization Unit loads Unit load devices Weighing out © 2008 Prentice Hall

Product Characteristics Physical Characteristics Density of bulk materials Ability to withstand exposure to elements Respiration Chemical Characteristics Incompatible products Products requiring chemicals Characteristics must be made known to consumers © 2008 Prentice Hall

Figure 5-1: Portion of fabric care label for Levi’s jeans sold in Japan © 2008 Prentice Hall

Product Characteristics Hazardous Cargo Explosives Compressed gases Flammable liquids Oxidizers Poisons Radioactive materials Corrosive materials © 2008 Prentice Hall

Product Characteristics Environmental Protection Reduce packing materials used Use packaging materials that are more environmentally friendly with recycled content Use reusable containers Retain or support services that collect used packaging and recycle it Pallet shredder © 2008 Prentice Hall

Packaging Fundamentals Building-blocks concept Smallest unit is consumer package Each unit is stocked within the next larger one to protect the product Packaging refers to materials used for the containment, protection, handling, delivery, and presentation of goods Serves three general functions To promote To protect To identify (label) the relevant product

Promotional and Protective Functions of Packaging Enclose materials Restrain materials from undesired movement Separate contents to prevent undesired contact Cushion contents from outside vibrations and shocks Support the weight of identical containers stacked above Position the contents to provide maximum protection Provide for uniform weight distribution Provide exterior surface for labeling Be tamperproof Be safe for consumers or others © Pearson Education, Inc. publishing as Prentice Hall

Checklist for Box Users (Figure 5-4) YOUR PRODUCT 1. Have you given your box maker a description of your product and its use, the exact dimensions, weight and physical characteristics? 2. Is the product likely to settle or shift? 3. Is it perishable, fragile, or hazardous in any way? 4. Will it need extra protection against vibration, impact, moisture, air, heat or cold? 5. Will it be shipped fully assembled? 6. Will more than one unit be packed in a box? 7. Will accessories, parts or literature be included with the product? 8. Have you provided your box maker with a complete sample of your product as it will be packed?

Checklist for Box Users (Figure 5-4) YOUR PACKING OPERATION Is your box inventory adequately geared to re-order lead time? Is your box inventory arranged to efficiently feed your packing lines? Is your inventory of boxes properly stored? Will you be setting up the boxes on automatic equipment? (lf so, what type? Size? Method of closure?) Will your product be packed automatically? (lf so, with what type of equipment?) lf more than one unit or part goes into each box, have you determined the sequence? Will inner packing — shells, liners, pads, partitions—be inserted by hand? Is your closure system—tape, stiches, glue—compatible with the box, packing line speed, customer needs and recycling considerations? Will the box be imprinted or labeled? Will a master pack be used for a multiple of boxes to maintain cleanliness or appearance?

Checklist for Box Users (Figure 5-4) YOUR STORAGE 1. Have you determined the gross weight of the filled box? 2. Does the product itself help support weight in stacking? 3. Will the bottom box have to support the full weight in warehouse stacking? 4. Will boxes be handled by lift trucks which use clamps, finger lifts or special attachments? 5. Will filled boxes be palletized? (The size of pallet and pallet pattern may justify a change in box design or dimensions, if only to reduce or eliminate overhang.) 6. Would a change in box style or size make more efficient use of warehouse space? 7. Will filled boxes be subject to unusual conditions during storage—high humidity, extreme temperatures. etc.? 8. Is the product likely to be stored outdoors at anytime during its distribution? 9. Would color coding simplify identification of various packed products?

Checklist for Box Users (Figure 5-4) YOUR SHIPPING Have you reviewed the appropriate rules of the transportation service you intend to use (rail, truck, air, parcel post, etc.)? Is your container authorized for shipment of your product? If the package is not authorized, have you requested appropriate test shipment authorization from the carrier? Does your product require any special caution or warning label or legend for shipment? Have you determined the actual inside dimensions of the transportation vehicle so that you can establish how your filled boxes will be stacked or braced?

Checklist for Box Users (Figure 5-4) YOUR CUSTOMER Does your customer have any special receiving, storage or handling requirements that will affect box design? Will the box be used as part of a mass display? Is the box intended as a display-shipper? Will it contain a separate product display? Will it be used as a carry-home package, requiring a carrying device? Does it need an easy-opening feature? Can surface design. symbols or colors relate to promotional materials or to other products of the same corporate family? Should instructions or opening precautions be printed on the box? Can the box be made to better sell your product?

Figure 5-5: Boxmaker’s Certificate (BMC) © 2008 Prentice Hall

Package Testing and Monitoring A package system requires 3 types of information to design Severity of the distribution environment Fragility of the product Performance characteristics of various cushion materials

Package Testing and Monitoring Vibrations Dropping Horizontal impacts Compression Overexposure to extreme temperatures or moisture Rough handling © 2008 Prentice Hall

Figure 5-8: Results of Compression Test © 2008 Prentice Hall

Figure 5-9: Kaiser Aluminum’s Moisture-Alert Label

Packaging Labeling Retroflective labels Batch numbers Weight Specific contents Instructions for use Information to allow passage through customs Compliance labeling One- or two-dimensional bar codes Smart labels or RFID labels © 2008 Prentice Hall

Labeling Hazardous Materials Requirements involve Governmental regulations address labeling of hazardous materials Requirements involve Labeling Packaging and repackaging Placing warnings on shipping documents Notifying transportation carriers in advance Globally Harmonized System of Classification and Labeling of Chemicals (GHS) is a global system to classify and label hazardous materials.

Figure 5-6: Examples of Shipping Labels © 2008 Prentice Hall

Figure 5-7: A handheld laser scanner scanning labels on a pallet load of product sitting in a warehouse rack © 2008 Prentice Hall

Issues in Packaging Environmental Protection Reduce packing materials used Use packaging materials that are more environmentally friendly with recycled content Use reusable containers (closed-loop system) Retain or support services that collect used packaging and recycle it (closed-loop system)

Issues in Packaging Metric System U.S., Liberia, and Myanmar (formerly Burma) are the only 3 countries in the world that do not use the metric system of measurement Increasing pressure on U.S. exporters to market their products overseas in metric units

Identifying Packaging Inefficiencies Building-blocks concept is useful for analyzing packaging inefficiencies. Packaging inefficiencies can have a number of undesirable logistics consequences including: Increased loss Increase damage Slower materials handling Higher storage costs Higher transportation costs

Packaging’s Influence on Transportation Considerations Carrier’s tariffs and classifications influence the type of packaging and packing methods that must be used. Carriers established classifications for two main reasons: Packaging specifications determined by product density lead to the best use of the equipment’s weight and volume capabilities Carrier specifications for protective packaging reduce likelihood of damage to products thus reducing the loss and damage claims filed against the carrier

Figure 5-10: A Pallet Shredder designed to reduce the cubic volume of wooden pallets and crating so that they cost less to transport © 2008 Prentice Hall

Unit Loads in Materials Handling A unit load (unitization) refers to consolidation of several units (cartons or cases) into larger units to improve efficiency in handling and to reduce shipping costs. Source: http://cscmp.org/digital/glossary/glossary.asp Handling efficiency can be facilitated by mechanical devices (pallet jack or forklift) as well as by using a pallet or skid.

Unit Loads in Materials Handling Advantages Additional protection Pilferage is discouraged More fragile items can be stacked inside the load Mechanical devices can be substituted for hand labor Disadvantages Provides large quantity that sometimes is of limited value to resellers dealing in smaller quantities Must use mechanical or automated device to move © Pearson Education, Inc. publishing as Prentice Hall

Unit Loads in Materials Handling A unit load is one or more boxes secured to a pallet or skid so that boxes can be handled by mechanical means Rainbow pallet load Unitization describes this type of handling Slip sheet can be used in place of pallet Saves vertical room Requires more care when moving © 2008 Prentice Hall

Unit Loads in Materials Handling Basic unit is a pallet or skid Can be constructed from wood, wood composites, plastic, paper, and metal Each pallet material has advantages and disadvantages Should be less than 50 pounds Pallet or skid alternatives Slip sheet Shrink-wrap © Pearson Education, Inc. publishing as Prentice Hall

Unit Loads in Material Handling Beyond the unit load Use of load-planning software Bracing Inflatable dunnage bags Load is subjected various forces including Vibration Roll Pitch Weighing out © Pearson Education, Inc. publishing as Prentice Hall

Figure 5-11: A Battery Powered Lift Truck Used for Stock Picking © 2008 Prentice Hall

Figure 5-15: Various Types of Intermodal Surface Containers © 2008 Prentice Hall

Materials Handling Materials handling refers to the “short-distance movement that usually takes place within the confines of a building such as a plant or DC and between a build and a transportation service provider.” Source: John J. Coyle, C. John Langley, Jr., Brian J. Gibson, Robert A. Novack, and Edward J. Bardi, Supply Chain Management: A Logistics Perspective, 8th ed. (Mason, OH: South-Western Cengage Learning, 2009), Appendix 11-A. How the products are handled depends on whether they are packaged or in bulk Handling may change the characteristics of the product

Materials Handling Principles 10 Material Handling Principles Include: Planning Standardization Work Ergonomic Unit load Space utilization System Automation Environmental Life cycle cost Source: “The Ten Principles of Material Handling,” www.mhia.org.

Materials Handling Equipment Two categories of handling equipment Storage Shelves Racks Bins Handling Conveyor systems Lift trucks Carts Cranes

Materials Handling Equipment The choice of handling equipment can influence the type of storage equipment. The choice of storage equipment can influence the type of handling equipment.

Materials Handling Equipment Material handling equipment can also be categorized as: Labor intensive Mechanized Automated Sufficient volume is needed to justify high cost of automated equipment © Pearson Education, Inc. publishing as Prentice Hall

Materials Handling Equipment An organization’s order picking and assembly system can also influence the type of handling equipment. Picker-to-part systems Part-to-picker systems

Case 5-1 Let There Be Light Lamp Shade Company Company Facts: Located Madison, Wiscinsin Product Facts: 5,400 identical Lamp Shade (to Asia) Design Options: Style A: cylinder, 11” x 11” Style B & C: Cone-shaped

Case 5-1 Let There Be Light Lamp Shade Company Transportation to Port of Oakland: Land rate: $1,000 per 40-ft container (8’w, 8.5’h, 40’ l) Max weight: 44,000 lbs Transportation from Port of Oakland to overseas port: Ocean rate: $22 per ton (2,000 lbs) Measurement ton: 40 ft3 = 1 ton Insurance Cost: 2% of the value of shipment

Case 5-1 Let There Be Light Lamp Shade Company Packaging Info: Style A Style B Style C Manuf. Cost (per piece) $4.00 $5.00 $6.00 Package size 12"x12"x12" 12"x12"x48" 12"x12"x50" # of pieces per pack 1 6 10 Package Cost (each) $0.60 $2.00 $3.00 Package weight (lbs) 62 101

Case 5-1 Let There Be Light Lamp Shade Company Discussions: #1: How many style A shades can be loaded into an intermodal container? #2: How many style B shades can be loaded into an intermodal container? #3: How many style C shades can be loaded into an intermodal container? #4: What are the total costs of delivering the style A shades to the port of importation? #5: What are the total costs of delivering the style B shades to the port of importation? #6: What are the total costs of delivering the style C shades to the port of importation?